KR20210119322A - Method for manufacturing raw material roll and method for predicting defect occurrence of raw material roll - Google Patents

Abstract

Provided is a method of manufacturing a fabric roll, capable of suppressing occurrence of defects. According to one embodiment, the method of manufacturing the fabric roll includes: transferring a film extruded from a die; forming a fabric roll by winding the film around a winding shaft while relatively oscillating at least one of the winding shaft and the film in a width direction of the film with a constant oscillation width; acquiring a thickness profile in the width direction of the film; calculating a corrected thickness profile by moving-averaging the thickness profile based on the oscillation width; determining whether thickness adjustment is necessary or not based on at least one of a first difference between a thickness at a first end of the fabric roll in the width direction and a maximum thickness and a second difference between a thickness at a second end of the fabric roll in the width direction and a maximum thickness in the corrected thickness profile; and adjusting an extrusion condition of the film from the die when the thickness adjustment is determined to be necessary in the determining.

Description

Fabric roll manufacturing method and defect occurrence prediction method

The present invention relates to a method for manufacturing a roll of fabric and a method for predicting occurrence of defects.

A film (for example, an optical film) is formed using the extrusion method using the die|dye (T-die in patent document 1), as described in patent document 1, for example. A fabric roll is obtained by winding up the film continuously extruded from T-die on a take-up shaft.

Patent Document 1: Japanese Patent Laid-Open No. 2005-186377

When winding up a film and manufacturing a fabric roll, the thickness of a film is normally controlled so that thickness distribution of the film in the width direction of a film may be made uniform. However, in this case, it exists in the tendency for the edge part of a fabric roll to generate|occur|produce the appearance defect like protruding radially outward. On the other hand, according to the knowledge of the inventors of the present application, when the thickness of the film is adjusted in order to reduce the above-described defect in appearance, defects (for example, deformation defects such as wrinkles) occur due to air entrainment or the like at the time of winding the film.

Therefore, one aspect of the present invention aims to provide a method for manufacturing a roll of fabric capable of suppressing the occurrence of defects. Another aspect of the present invention aims to provide a method for predicting the occurrence of defects in a roll of fabric.

The method for manufacturing a roll of fabric according to an aspect of the present invention comprises a step of conveying a film continuously extruded from a die, and at least one of a winding shaft and the film in the width direction of the film with a constant oscillation width. A step of forming a roll of fabric by winding the film on the take-up shaft at a rate, a step of acquiring a thickness profile along a direction transverse to the transport direction of the film transported from the die to the take-up shaft, and the thickness profile a step of calculating a crystal thickness profile by moving average based on the oscillate width, and in the crystal thickness profile, the thickness and the width at a position corresponding to the first end in the width direction of the fabric roll. Based on at least one of the thickness at the position corresponding to the 1st difference of the maximum thickness in a direction and the 2nd end on the opposite side to the said 1st end in the said width direction of the said fabric roll, and the 2nd difference of the said maximum thickness to determine whether the thickness adjustment of the film is necessary and not necessary; A step of adjusting the conditions is provided.

The inventor of the present application relates to a fabric roll manufactured based on at least one of the first order and the second order obtained based on the correction thickness profile and that the corrected thickness profile more appropriately reflects the shape of the fabric roll. It was discovered that the presence or absence of occurrence of a defect in the present invention was predictable. In the manufacturing method of the said raw material roll, based on at least one of the said 1st order and a 2nd order, when it is determined that thickness adjustment is necessary, the process (determination process) of determining the necessity and necessity of thickness adjustment, the film of It has a process (adjustment process) of adjusting thickness. Since the occurrence of a defect can be predicted based on at least one of the first order and the second order, when the defect occurrence is predicted, it can be determined that thickness adjustment is necessary in the determination step. In that case, in order to implement an adjustment process, a fabric roll can be manufactured, suppressing defect generation|occurrence|production.

In the determining step, the determination may be made based on the difference between the thickness and the maximum thickness at the position of the far end which is the farther end from the position of the maximum thickness among the first end and the second end.

The manufacturing method of the raw material roll which concerns on one Embodiment further comprises the process of cutting the length of the said width direction of the said film to a predetermined size during conveyance of the said film, In the process of forming the said raw material roll, the said predetermined size The raw-cut film may be wound around the winding shaft. Thereby, a fabric roll of a predetermined size can be manufactured.

In the step of adjusting, the opening of the lip included in the die may be adjusted. Thereby, the thickness of a film can be adjusted.

In the method for predicting the occurrence of defects in a fabric roll according to another aspect of the present invention, the continuously conveyed film is relatively oscillated on at least one of the winding axis and the film in the width direction of the film with a constant oscillation width while the winding axis A step of forming a roll of fabric by winding to a step, a step of acquiring a thickness profile along a direction transverse to the conveying direction of the film during conveyance, and a moving average of the thickness profile based on the oscillation width to obtain a corrected thickness profile The process of calculating, the said correction thickness profile WHEREIN: The 1st difference between the thickness in the position corresponding to the 1st end of the said width direction of the said fabric roll, and the maximum thickness in the said width direction, and the said width of the said fabric roll a step of predicting the presence or absence of occurrence of defects in the fabric roll based on at least one of a thickness at a position corresponding to a second end opposite to the first end in the direction and a second difference of the maximum thickness; .

As mentioned above, this inventor is based on at least one of the said 1st difference obtained based on the said correction thickness profile and that the said correction thickness profile is reflecting the shape of a fabric roll more appropriately, and the said correction thickness profile, , found that the presence or absence of defects in the fabric roll to be manufactured was predictable. Since the defect generation|occurrence|production prediction method of the said fabric roll is equipped with the process (prediction process) of predicting the presence or absence of a defect generation|occurrence|production based on at least one of the said 1st order and a 2nd order, defect generation|occurrence|production can be predicted. When it is predicted that there is a possibility that a defect will generate|occur|produce in a prediction process, since the process, such as adjusting the thickness of a film, can be performed, for example, a fabric roll can be manufactured, suppressing the occurrence of a defect.

In the estimating step, the prediction may be made based on a difference between the thickness at the position of the far end, which is the farther end from the position of the maximum thickness, and the maximum thickness among the first end and the second end.

According to one aspect of the present invention, it is possible to provide a method of manufacturing a fabric roll capable of suppressing the occurrence of defects. Another aspect of the present invention can provide a method for predicting the occurrence of defects in a roll of fabric.

1 is a schematic diagram for explaining a method of manufacturing a roll of fabric according to an embodiment of the present invention.
2 is a view for explaining a process of winding a film on a winding shaft.
3 is a view for explaining a case in which the period is set so as to be equally spaced with respect to the diameter of the winding.
It is a schematic diagram of the end surface of the fabric roll wound with the cycle demonstrated using FIG.
It is a figure which shows an example of the thickness profile of a film.
It is a figure for demonstrating an example of the calculation method of a correction thickness profile.
It is a figure which shows an example of a crystal thickness profile.
8 : is a figure which showed the width direction distribution of the radius of the fabric roll 10 formed when the thickness profile shown in FIG. 7 was acquired.
9 is a view showing a thickness profile and a corrected thickness profile in the case of manufacturing the fabric roll (A).
10 is a view showing a thickness profile and a corrected thickness profile in the case of manufacturing the fabric roll (B).
11 is a view showing a thickness profile and a corrected thickness profile in the case of manufacturing the fabric roll (C).

EMBODIMENT OF THE INVENTION Hereinafter, embodiment of this invention is described with reference to drawings. In the drawings, the same reference numerals are attached to the same or corresponding parts, and overlapping explanations are omitted. Dimensional ratios in the drawings do not necessarily coincide with those described.

1 and 2 are schematic views for explaining a method of manufacturing a roll of fabric according to an embodiment of the present invention. The fabric roll 10 is a roll body of the elongate film 12 .

The film 12 is, for example, an optical film. Examples of the material of the optical film include an acrylic resin, a cycloolefin resin, a styrene resin, an acrylonitrile-butadiene-styrene copolymer resin, and a polycarbonate resin.

The film 12 is, for example, a resin film, and in the present embodiment, the film 12 is a thermoplastic resin film.

As a thermoplastic resin, a general-purpose thermoplastic resin may be sufficient and engineering plastics may be sufficient. Examples of the thermoplastic resin include acrylic resin, cycloolefin resin, styrene resin, methyl methacrylate-styrene copolymer resin, methyl methacrylate-butadiene-styrene copolymer resin, polyvinyl chloride resin, low-density polyethylene, high-density polyethylene, straight chain. Polyethylene resin such as low density polyethylene, polypropylene resin, acrylonitrile-butadiene-styrene copolymer (ABS) resin, acrylonitrile-styrene copolymer resin, cellulose acetate resin, ethylene-vinyl acetate copolymer resin, acrylic-chlorinated polyethylene Copolymer resin, ethylene vinyl alcohol resin, fluororesin, polyacetal resin, polyamide resin, polyethylene terephthalate resin, polybutylene terephthalate resin, polycarbonate resin, polysulfone resin, polyethersulfone resin, methylpentene resin, Polyarylate resin, resin containing ethylenically unsaturated monomer unit containing alicyclic structure, polyphenylene sulfide resin, polyphenylene oxide resin, polyether ether ketone resin, polyvinyl chloride elastomer, chlorinated polyethylene, ethylene-ethyl acrylate copolymer Copolymer resins, thermoplastic polyurethane elastomers, thermoplastic polyester elastomers, ionomer resins, styrene-butadiene block polymers, ethylene-propylene rubbers, polybutadiene resins, and acrylic elastomers are mentioned.

The film 12 may be a laminate of a thermoplastic resin film. In this case, the thermoplastic resin constituting each thermoplastic resin layer to be laminated is at least one selected from an acrylic resin, a cycloolefin resin, a styrene resin, an acrylonitrile-butadiene-styrene copolymer resin, and a polycarbonate resin. it is preferable

As a specific example of the said thermoplastic resin, the thermoplastic resin etc. of Unexamined-Japanese-Patent No. 2012-224057 and Unexamined-Japanese-Patent No. 2013-014136 are mentioned. The above-mentioned thermoplastic resin may contain various additives. Examples of the additive include a light diffusing agent, an ultraviolet absorber, a surfactant, an impact resistance agent, a polymer type antistatic agent, an antioxidant, a flame retardant, a lubricant, a colorant such as a dye or a pigment, and acrylic rubber particles.

An example of the thickness t of the film 12 is 100 μm or less. The thickness t of the film 12 is, for example, 20 µm or more.

The fabric roll 10 is manufactured by continuously forming the film 12 by extrusion molding, for example, and winding it up on the take-up shaft 14 . The total length of the film 12 for forming one fabric roll 10 is, for example, 1,000 m or more. The upper limit of the total length of the fabric roll 10 is 10,000 m or less - 8000 m or less, for example.

When manufacturing the fabric roll 10, as schematically shown in FIG. 1, the pellets P formed of the material of the film 12 are supplied to the extruder 16 and melted in the extruder 16. The molten resin in the extruder 16 is supplied to the die 18 . The die 18 may be a known die used for manufacturing the film 12 . In this embodiment, die 18 is a T die.

The molten resin is continuously extruded from the lip 18a which is the discharge port of the die 18, and the film 12 is formed by shaping|molding and cooling. The resin continuously extruded from the die 18 is guided by the guide roll 20, and the film-shaped resin that has passed through the guide roll 20 is continuously conveyed toward the take-up shaft 14 (conveying step). The conveying speed is, for example, 5 m/min to 200 m/min, preferably 10 m/min to 150 m/min, more preferably 20 m/min to 100 m/min. For example, the pair of guide rolls 20 provided in the vicinity of the lip 18a functions also as a cooling roll that solidifies the high-temperature film 12 extruded from the die 18 by cooling with a cooling unit including a cooling roll or the like. do. At least one guide roll may be provided between the guide roll 20 shown in FIG. 1 and the take-up shaft 14 . The film-like resin is the film 12 . In addition, a well-known element in melt extrusion molding (for example, a backup roll used in pinch molding for cooling by being sandwiched between a roll and a roll furnace, an air knife for pressing the resin to a cooling roll, etc.) may be used. Hereinafter, for the sake of simplification of explanation, it may be simply referred to as "the film 12 is formed from the die 18".

The film 12 conveyed by the winding shaft 14 is wound up in roll shape by the winding shaft 14, and the fabric roll 10 is obtained (fabric roll formation process). For example, when winding up the film 12 on the winding shaft 14, you may wind up the film 12, giving predetermined touch pressure to the surface of the film 12 with a touch roll.

With respect to the film 12 after the cooling, further steps such as a surface treatment step (eg, hard coat application, drying treatment, etc.), an stretching step, a lamination step with other resins, etc. may be performed before winding as needed. .

As shown in FIG. 1 and FIG. 2, you may trim the length of the width direction of the film 12 to the product size (predetermined size) with the trimming device 22 during conveyance of the film 12. The trimming device 22 may have, for example, a pair of cutters 22A, 22B, as shown in FIG. 2 . The distance (distance in the width direction of the film 12) between a pair of cutter 22A, 22B respond|corresponds to a product size. By cutting the film 12 with a pair of cutters 22A, 22B, the film 12 is trimmed to the product size. The predetermined size at the time of trimming the film 12 is not limited to the product size.

In the form of trimming the film 12 with the trimming device 22 , the film 12 of the product size is wound by the winding shaft 14 . The trimming device 22 (eg, a pair of cutters 22A and 22B) may oscillate in synchronization with the oscillation of the take-up shaft 14 . Hereinafter, unless otherwise specified, a mode in which the film 12 extruded from the die 18 is trimmed to the product size by the trimming device 22 will be described. In FIG. 2, on the downstream side of the trimming apparatus 22, illustration of the part other than the area|region cut to the product size among the film 12 is abbreviate|omitted.

The example of the width L of the fabric roll 10 is 100 mm - 3000 mm, More preferably, they are 500 mm - 2500 mm. When not trimming, the width L0 of the film 12 is the same as the width L of the raw material roll 10 . When trimming, the width L0 of the film 12 before trimming is the length which considered the width|variety cut by trimming.

When the film 12 is wound around the winding shaft 14 , the film 12 is wound while relatively oscillating (oscillating) at least one of the film 12 and the winding shaft 14 . Oscillation is performed in the width direction of the film 12 (direction orthogonal to the long direction of the film 12) under predetermined oscillation conditions (eg, period, oscillation width, etc.). In the present embodiment, as shown in FIG. 2 , the winding shaft 14 and the trimming device 22 are oscillated. When manufacturing one fabric roll 10, if a cycle is included a plurality of times from the start of the production to the end of the production, immediately before the end of the formation of the fabric roll 10, for example, the cycle is longer than the other cycle. It may be short, and the oscillation position does not need to fully reach the edge part. The oscillate width w may be a width at which the ridge differences in the thickness profile are averaged in the width direction. For example, the oscillate width w is about several 10 mm to 100 mm. The period C0 of the oscillation may be set to be equally spaced with respect to the winding diameter or may be set to be equally spaced with respect to the winding length.

The period C0 of the oscillation will be described with reference to FIGS. 3 and 4 . 3 and 4 are diagrams for explaining a case in which the period C0 is set at equal intervals with respect to the winding diameter. In FIG. 3, the case where the area|region of width L0 is trimmed from the film 12 of width L is shown. The width L1 in the figure is the length obtained by adding the oscillate width w to the width L. 4 : is a schematic diagram of the end surface (end surface at the time of seeing from the direction of the winding-up shaft 14) of the fabric roll 10 wound with the cycle demonstrated using FIG.

The black square mark in Fig. 3 indicates the oscillation end (the position where the cutter 22A (cutter 22B) is moved to the right the most) on the right (one side) in the figure with respect to the oscillation center, and the black The colored round mark indicates the oscillation end (the position at which the cutter 22A (the cutter 22B) has moved the most to the left) on the left side (the other side) in the drawing with respect to the oscillation center. The period C0 is a distance between two adjacent square marks (or two adjacent round marks) in the longitudinal direction of the film 12 . The meaning of the square mark and the round mark shown in FIG. 4 is the same as that of FIG. In the example shown in FIG. 3 and FIG. 4, in the radial direction (winding radial direction) of the raw material roll 10, as shown in FIG. 4, between the said two adjacent square marks (or two adjacent round marks) The period C0 is controlled so that the distance C1 becomes constant. Accordingly, the period C0 becomes longer as the film 12 is wound. When oscillating with a constant cycle C0 with respect to the winding diameter, the cycle C0 may be adjusted while the winding diameter is observed by an operator or an apparatus.

When the period C0 is set to be at equal intervals with respect to the winding length, the period C0 is constant along the long direction of the film 12 . However, as mentioned above, just before the end of formation of the fabric roll 10, the said period C0 may become short, for example. When the period C0 is constant with respect to the winding length, in the direction of the winding diameter, the distance C1 between adjacent square marks shown in FIG. 4 is shortened immediately before the winding is finished.

With reference again to FIG. 1, the manufacturing method of the fabric roll 10 which concerns on this embodiment is demonstrated. In the manufacturing method of the raw material roll 10, the thickness t of the film 12 conveyed from the die 18 to the winding shaft 14 is measured with the thickness gauge 24, and the film 12 is conveyed. A thickness profile is obtained along a direction transverse to the direction (thickness profile acquisition process). In this embodiment, unless otherwise specified, a thickness profile along the width direction is obtained.

The thickness measuring device 24 is a measuring device capable of in-line measurement. An example of the thickness gauge 24 is a non-contact thickness gauge. An example of a non-contact thickness measuring device is an X-ray transmission type, an infrared (IR) transmission type, a laser type, or a reflection spectroscopy type thickness measuring device. In FIG. 1, the example using one thickness measuring device 24 is shown. However, for example, the thickness may be measured using a plurality of thickness gauges 24 arranged along the width direction. You may perform thickness measurement, moving one thickness gauge 24 in the width direction of the film 12. When measuring thickness while moving the thickness gauge 24 in the width direction of the film 12, since the film 12 is conveyed, thickness is measured along the direction inclined with respect to a conveyance direction. The position of the thickness gauge 24 between the die 18 and the winding shaft 14 is not limited. 1, in the conveyance direction of the film 12, the thickness of the film 12 which is not trimmed may be measured, and the thickness of the film 12 of the trimmed product size may be measured. When measuring the thickness of the untrimmed film 12, it is sufficient to measure at least the thickness of the region of the film 12 in consideration of the product size region and the oscillation width.

It is a figure which shows an example of the thickness profile of a film. In FIG. 5, the thickness profile of the film 12 according to the size of the fabric roll 10 is shown. 5 is an average thickness profile based on the measurement result of the thickness of the entire film 12 conveyed to form one roll 10 of the fabric. 5 , the horizontal axis indicates the position (mm) in the width direction of the film 12 before being trimmed by the trimming device 22 , and the vertical axis indicates the thickness t (µm).

A corrected thickness profile is computed by moving-averaging the obtained thickness profile based on the oscillation width|variety w of the winding shaft 14 (calculation process). In this specification, the oscillation width w is the sum of the magnitudes of the oscillation amplitudes (eg, w/2) at each of both sides of an arbitrary position.

The said correction thickness profile is obtained by calculating the moving average value based on the oscillation width|variety w with respect to arbitrary measurement positions in the film 12. As shown in FIG. The moving average value based on the oscillation width w with respect to the measurement position is a value obtained by averaging the measurement results of the area of ±w/2 in the width direction with the measurement position as the center. By calculating the same moving average value for each measurement position, it is possible to obtain a corrected thickness profile.

An example of the calculation method of a correction thickness profile is demonstrated using FIG. In the description of the calculation method, the following (a) to (g) are assumed.

(a) The thickness t is measured by the pitch along the width direction of the film 12 (henceforth "measuring pitch p" is called).

(b) The predetermined pitch is half (ie, w/2) of the oscillate width w.

(c) The width|variety of the film 12 wound as the raw material roll 10 is L. That is, the fabric roll 10 is manufactured by trimming a region having a length L in the width direction of the film 12 .

(d) The film 12 (width L) wound around the roll 10 is called a film 12A.

(e) Of the film 12, the area|region which contributes to the corrected thickness profile of the film 12A is called the film 12B.

(f) The measurement position of the thickness t in the film 12B is called _{X 1} , X ₂ , ..., X ₂₁ , X _{22 as shown in FIG. 5 .}

(g) the position of _{the film 12A corresponding to the position (X 2} , X ₃ , ..., X ₂₀ , X ₂₁ ) in the film 12B is Xa ₁ , Xa ₂ , ..., Xa ₁₉ , referred to as _{Xa 20 .}

From (b) and (c) above, the width L1 of the film 12B is the sum of the width L and the oscillation width w.

The crystal thickness profile of the film 12A is, the position (Xa ₁ ), the position (Xa ₂ ), ..., the position (Xa ₁₉ ), the position (Xa ₂₀ ) each thickness (hereinafter referred to as “crystal thickness”) is obtained by calculating as a moving average value based on the above-described oscillate width w.

For example, the corrected thickness of _{position Xa 1 is the average value of the thickness t of position X 1} , position X ₂ , and position X ₃ (ie, the sum of the thicknesses of the three measurement positions is equal to 3) divided value). Similarly, the corrected thickness of _{position Xa 2 is equal to the average value of the thickness t of position X 2} , position X ₃ , and position X ₄ (ie, the sum of the thicknesses of the three measurement positions is equal to 3) divided value). Similarly, the corrected thickness of _{position Xa 3 is the average value of the thickness t of position X 3} , position X ₄ , and position X ₅ (ie, the sum of the thicknesses of the three measurement positions is equal to 3 ) divided value). Hereinafter, the correction thickness of the position (Xa ₄ ), the position (Xa ₅ ), ..., the position (Xa ₁₉ ), and the position (Xa _{20 ) is similarly calculated.}

The crystal thickness profile of the film 12B is obtained by calculating the crystal thickness of each of the position Xa ₁ , the position Xa ₂ , the position Xa ₁₉ , and the position Xa _{20 as described above.} .

Although (b) is assumed in the above description, the measurement pitch p may be equal to or less than half of the oscillate width w.

It is a figure which shows an example of a crystal thickness profile. 7 : is a profile obtained by carrying out the moving average of the area|region of the width L1 shown in FIG. 3 among the film 12 based on the oscillation width|variety w at the time of manufacture of the fabric roll 10. The used oscillate width w was 80 mm (± 40 mm). The horizontal axis in FIG. 7 has shown the width direction position (mm) of the fabric roll 10. "OP" and "DR" shown in FIG. 7 are 1st end OP and 2nd end DR (end opposite to 1st end OP) in the width direction of the fabric roll 10. The corresponding position is indicated. The vertical axis in FIG. 7 represents the thickness (µm). The thickness tm1 shown in FIG. 7 corresponds to the thickness obtained by correcting the thickness t1 shown in FIG. 5 based on the crystal thickness profile, and the thickness tm2 is the thickness t2 shown in FIG. It corresponds to the thickness corrected based on

In the manufacturing method of the raw material roll 10, the necessity and necessity of thickness adjustment of the film 12 are determined based on a correction thickness profile (judgment process). Specifically, in the crystal thickness profile, the first difference and the second difference between the thickness at the position corresponding to the first end OP (hereinafter referred to as “thickness at the first end OP”) and the maximum thickness Based on at least one of the second difference between the thickness at the position corresponding to the end DR (hereinafter referred to as “thickness at the second end DR”) and the maximum thickness, the thickness adjustment of the film 12 is Decide what is necessary and what is not.

Among the first end OP and the second end DR, an end farther from the position of the maximum thickness of the crystal thickness profile is referred to as a far end. In this case, for example, based on the maximum thickness in a crystal thickness profile, and the thickness in the position of a far end, the necessity and necessity of thickness adjustment of the film 12 can be determined. For example, when the difference between the thickness at the far end and the maximum thickness is a predetermined value or more, it may be determined that thickness adjustment is necessary. The predetermined value may be determined in advance by, for example, a simulation or a preliminary experiment.

When it is determined in the determination process that thickness adjustment is necessary, in the determination process, so that thickness adjustment is not determined (for example, so that the thickness and the maximum thickness at the position of the far end become less than the predetermined value), the die The extrusion conditions of the film 12 from (18) are adjusted (adjustment process). For example, the thickness is adjusted so that the thickness around the position of the maximum thickness becomes thin. Thickness may adjust the open state of the area|region which should be thickness-adjusted among the ribs 18a in the width direction of the film 12, for example. When the die 18 is a T die, the open state (lip openness) of the lip 18a can be adjusted by opening and closing the choke bar bolts arranged in the width direction of the die 18 . When the choke bar bolt is opened, the discharge amount of the resin extruded from the die 18 increases, and the thickness of the film 12 increases. When the choke bar bolt is closed, the discharge amount of the resin extruded from the die 18 decreases. The thickness of the film 12 decreases. For example, in the crystal movement thickness profile, the lip opening degree is adjusted within a range including a predetermined range (for example, 100 mm) on the left and right from the position corresponding to the maximum value (the range in the width direction considering oscillation), Adjust so that the average film thickness near the maximum value decreases. Alternatively, the thickness of the film 12 may be adjusted by adjusting the temperature of the die 18 .

When performing an adjustment process, the fabric roll 10 is manufactured on the extrusion conditions after adjustment. Moreover, the process from the conveyance process of forming and continuously conveying the film 12 to an adjustment process is repeated until it determines with thickness adjustment being unnecessary in a determination process.

In the manufacturing method, the film 12 is wound while oscillating the winding shaft 14 . Therefore, even if distribution of thickness arises in the width direction of the film 12, the influence of thickness distribution can be reduced.

In the said manufacturing method, the said correction thickness profile is computed based on a film thickness profile. According to the knowledge of this inventor, this correction thickness profile has shown the shape of the fabric roll 10 more suitably.

This point is demonstrated using FIG.5, FIG.7, and FIG.8. 8 : is a figure which showed the width direction distribution of the radius of the fabric roll 10 formed when the thickness profile shown in FIG. 7 was acquired. The horizontal axis in a figure has shown the width direction position of the fabric roll 10. The horizontal axis, OP, and DR in FIG. 8 are the same as in the case of FIG. The vertical axis in FIG. 8 has shown the radius of the fabric roll 10. As shown in FIG. Comparing FIGS. 5, 7 and 8, the modified thickness profile shown in FIG. 7 is more consistent with the width direction distribution of the radius of the fabric roll 10 shown in FIG. 8 than the thickness profile shown in FIG. can be understood

This inventor discovered that the presence or absence of defect generation in the fabric roll 10 manufactured was predictable based on at least one of the said 1st order and a 2nd order.

In the manufacturing method of the said raw material roll 10, in a determination process, the necessity and necessity of thickness adjustment are determined based on at least one of the said 1st order and a 2nd order. In addition, when it determines with thickness adjustment being necessary, an adjustment process is implemented.

As described above, since the occurrence of defects can be predicted based on at least one of the first order and the second order, when the defect occurrence is predicted, it is sufficient to determine that thickness adjustment is necessary. In this case, as mentioned above, in order to implement an adjustment process, the fabric roll 10 can be manufactured, suppressing defect generation|occurrence|production.

In the form in which the trimming device 22 and the winding shaft 14 are synchronized and oscillated, in the first end OP and the second end DR of the fabric roll 10 , the radius of the fabric roll 10 is It is possible to manufacture the fabric roll 10 in which the end faces of the films 12 stacked in the direction coincide.

An experiment that verified that the occurrence of defects can be predicted with the judgment conditions indicated in the judgment process will be described. Here, based on the difference between the thickness and the maximum thickness at the position of the far end, which is the far end, with respect to the position of the maximum thickness among the first end OP and the second end DR, the thickness adjustment of the film 12 is Cases of determining necessity and necessity were verified.

In the verification experiment, three fabric rolls were manufactured by the method described with reference to FIGS. 1 and 2 .

The three fabric rolls are called a fabric roll (A), a fabric roll (B), and a fabric roll (C). The material of the film 12 constituting the fabric rolls A to C was the same acrylic resin. In the three fabric rolls A-C, the extrusion conditions for forming the film 12 were the same. The thickness of the film 12 was measured while moving one thickness gauge 24 in the width direction of the film 12 . The trimming device 22 and the winding shaft 14 were synchronized and oscillated. The oscillate width w was 80 mm (±40 mm). The oscillation was performed with the period C0 set so that it might become an equal interval with respect to the winding diameter, observing the winding diameter. In the verification experiment, a pair of cutters 22A and 22B were used for the trimming device 22 .

9, 10 and 11 show the corrected thickness profile in the case of manufacturing three fabric rolls (A), fabric rolls (B), and fabric rolls (C). The horizontal axis of FIGS. 9-11 has shown the width direction position of the fabric rolls A-C. The meanings of OP and DR in FIGS. 9 to 11 are the same as in the case of FIGS. 7 and 8 . The vertical axis of FIGS. 9-11 has shown the thickness t (micrometer).

In the corrected thickness profile corresponding to the fabric rolls A to C shown in FIGS. 9 to 11 , the difference (first order) between the thickness t _OP and the maximum thickness t _{max at the first end OP} And the difference (second difference) between the thickness (t _DP ) and the maximum thickness (t _max ) in the second end (DR) was shown in Table 1. In addition, as a result of confirming the presence or absence of defects in the fabric rolls A to C, defects (wrinkle-shaped deformation defects) occurred in the regions shown in Table 1.

From FIG. 9, in the corrected thickness profile corresponding to the fabric roll A, since the maximum thickness is located in the 1st end OP side, 2nd end DR is a far end. From Table 1, in the fabric roll A, the defect had generate|occur|produced at the 2nd end DR side which is a far end. From FIG. 10, in the corrected thickness profile corresponding to the fabric roll B, since the maximum thickness is located in the 2nd end DR side, the 1st end OP is a far end. From Table 1, in the fabric roll B, the defect had generate|occur|produced on the 1st end OP side which is a far end. From FIG. 11, in the corrected thickness profile corresponding to the fabric roll C, since the maximum thickness is located in the 1st end OP side, 2nd end DR is a far end. From Table 1, in the fabric roll C, the defect had generate|occur|produced at the 2nd end DR side which is a far end. Therefore, based on the results of Table 1, it was found that the occurrence of defects can be predicted by, for example, setting the predetermined value to 0.13 µm, preferably 0.11 µm.

As mentioned above, based on at least one of the said 1st order and a 2nd order, the presence or absence of the defect generation|occurrence|production in the fabric roll 10 manufactured is predictable. That is, the determination conditions in a determination process correspond to the prediction conditions of the presence or absence of generation|occurrence|production of a defect. Therefore, the said determination process corresponds to the prediction process of predicting the presence or absence of a defect. Therefore, the raw material roll formation process, the thickness profile acquisition process, a calculation process, and a determination process (corresponding to a prediction process) in the manufacturing method of the said fabric roll respond|correspond to the defect generation|occurrence|production prediction method.

As mentioned above, the experimental example was demonstrated with various embodiment of this invention. However, this invention is not limited to the illustrated embodiment and experimental example, The range shown by a claim is included, and it is intended that the meaning of a claim and equivalent and all changes within the range are included.

As a specific example of the determination process, only the difference between the thickness at the end corresponding to the far end among the first end OP and the second end DR and the maximum thickness is paid attention to, and the necessity and necessity of adjusting the thickness of the film 12 is eliminated. judged. However, for example, the necessity and necessity of thickness adjustment of the film 12 may be determined (or the presence or absence of a defect is predicted) using both of a 1st order and a 2nd order, for example. In this case, for example, the same predetermined value may be set for each of the first and second cars to determine whether or not thickness adjustment is necessary (or whether or not a defect will occur) may be determined (or the presence or absence of a defect may be predicted), and different predetermined values may be set to adjust the thickness It is also possible to determine the necessity and necessity of (or predict the presence or absence of occurrence of a defect). Determination of necessity or necessity of thickness adjustment based on the difference between the thickness and the maximum thickness at the end opposite to the far end (the end closest to the position of the maximum thickness among the first end OP and the second end DR) (or predicting the presence or absence of occurrence of a defect) may be performed.

In the said embodiment, the thickness of the width direction of the film 12 was measured in all the films 12 used for obtaining the one raw material roll 10, and the form which computed the corrected thickness profile was demonstrated. However, the crystal thickness profile may be calculated based on the measurement result of the thickness of the film 12 over the length of the region including the length for at least one period in the oscillation in the long direction of the film 12 . . In this case, when it is determined based on the corrected thickness profile that thickness adjustment is necessary, for example, manufacture of the fabric roll 10 can be stopped. When it is determined that thickness adjustment is necessary, since there is a high possibility that defects will occur in the fabric roll 10, as described above, by stopping the production of the fabric roll 10, the material of the film 12 can be effectively used. have.

It is not necessary to oscillate the trimming device 22 . Alternatively, while the trimming device 22 is oscillated, the winding shaft 14 may be fixed. In this case, the film 12 of the product size is oscillated with respect to the take-up shaft 14 and is wound around the take-up shaft 14 .

It is not necessary to trim the film 12 with the trimming device 22 . In this case, for example, the film 12 may be oscillated.

The above-described embodiment and various modifications may be appropriately combined without departing from the spirit of the present invention.

10… Fabric roll, 12… Film, 14... take-up shaft, 18… Die, 18a... Lip, OP… The first stage, DR... Column 2.

Claims (6)

A step of conveying the continuously extruded film from the die;
A step of forming a fabric roll by winding the film on the winding shaft while relatively oscillating at least one of a winding shaft and the film in the width direction of the film with a constant oscillation width;
obtaining a thickness profile along a direction transverse to the conveyance direction of the film conveyed from the die to the take-up shaft;
calculating a corrected thickness profile by moving-averaging the thickness profile based on the oscillate width;
The said correction thickness profile WHEREIN: In the said width direction of the thickness in the position corresponding to the 1st end in the said width direction of the said fabric roll, the 1st difference of the maximum thickness in the said width direction, and the said fabric roll. determining the necessity and necessity of adjusting the thickness of the film based on at least one of a thickness at a position corresponding to a second end opposite to the first end and a second difference of the maximum thickness;
In the step of determining, when it is determined that the thickness adjustment is necessary, the step of adjusting the extrusion conditions of the film from the die so as to correct the thickness profile of the film.
A method for manufacturing a roll of fabric comprising a. The determination according to claim 1, wherein in the determining step, the determination is made based on a difference between a thickness at a position of a far end, which is an end farther from the position of the maximum thickness, and the maximum thickness among the first end and the second end. A method for manufacturing a roll of fabric. 3. The method of claim 1 or 2,
During conveyance of the said film, the process of cutting the length of the said width direction of the said film to predetermined size is further provided,
In the process of forming the said fabric roll, the manufacturing method of the raw material roll which winds up the said film cut to the said predetermined size on the said winding shaft. The manufacturing method of the raw material roll as described in any one of Claims 1-3 which adjusts opening|release of the lip which the said die|dye has in the said adjustment process. A step of forming a roll of fabric by winding the continuously conveyed film on the winding shaft while relatively oscillating at least one of a winding shaft and the film in the width direction of the film with a constant oscillation width;
a process of acquiring a thickness profile along a direction transverse to the conveyance direction of the film being conveyed;
calculating a corrected thickness profile by moving-averaging the thickness profile based on the oscillate width;
The said correction thickness profile WHEREIN: The said 1st difference of the thickness at the position corresponding to the 1st end of the said width direction of the said fabric roll, and the maximum thickness in the said width direction, and the said 1st of the said width direction of the said fabric roll A step of predicting the presence or absence of occurrence of defects in the fabric roll based on at least one of the second difference between the thickness at the position corresponding to the second end on the opposite side to the end and the maximum thickness
A method for predicting the occurrence of defects in a fabric roll. The method according to claim 5, wherein in the predicting step, based on a difference between a thickness at a position of a far end, which is an end farther from the position of the maximum thickness, and the maximum thickness among the first end and the second end, Prediction, a method of predicting the occurrence of defects in a fabric roll.

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